Manufacture and Method of Installing, Notably Construction Panels Formed in a Closed Mold

ABSTRACT

The present invention concern the fabrication of panels ( 11 ) ( 12 ) in which the elements ( 2 ) are assembled by gussets ( 3 ) ( 13 ) during the preparation in the mold  
     A porous facing ( 5 ) constituting an external side that allows degassing ( 6 ) that is a result of the expansion of reactive products. The porous surface facing ( 5 ) is only impregnated ( 7 ) leaving the external surface of the panel rough for the future application of a coating.  
     The present invention allows for a perfect water tight seal ( 11 ) ( 12 ) between the panel, the ground and the frame with junction profile ( 16 ) and a tube for the injection of products ( 18 ) with no cavities to be filled-up after set-up.

[0001] The present invention concerns in general the concept and the onsite set-up of insulated, weather-proof panels for construction.

[0002] It is generally known that the fabrication of panels in moldedform does not present particular difficulty as long as these panels arenot made with the aid of expandable products, in this instance, ventsfor the degassing of air are required, allowing the excess air to bedriven out by the expansion of the foaming agents, a delicate operation.

[0003] The linking of the panels between themselves, in the set-upprocess is extremely complex and requires the presence of grooves formechanically linking two panels. It is also necessary to fill thesegrooves after building the elements on the construction site.

[0004] It is also common that the connection between the ground and thepanels is generally realised by incorporating metallic inserts duringfabrication of the concrete slab, or otherwise reserved areas, thatspecify the precise positioning that is not always respected, being seento be outside of the rules of the art.

[0005] It is also known that panel erected this way allows linking tothe upper part of the frame elements, but the stresses between theground and the frame are transmitted only by the panel elementsthemselves. This technique does not permit guarantee against a liftingof the frame during unfavorable climatic conditions.

[0006] The present invention concerns the seamless manufacture of apanel as well as the placing of these, without having to resort to anygrooves in order to guarantee a connection between the ground and theframe elements, within the rules of the art. The connection betweenpanels also makes possible a later filling of the cavities.

[0007] The present invention is characterized by the manufacture of apanel in a mold dimensioned to contain the elements inserted in thismolding:

[0008] 1) A sheet of wallboard (1) or other on the bottom of the mold .

[0009] 2) metal profiles (2) forming the frame of the panel (10) thisframe (2) is assembled into the mold itself, with the aid of metalgussets (3) anchored by spot-welding or metallic screws (15), thatapproach avoids the handling of the profiles (2) previously carried outwith difficulty.

[0010] 3) profiles (4) in synthetic materials for protection of thepanel edges during set-up, these profiles simply laying on the metalprofiles (3) maintaining the fiber plate (5) at a respectable distance.

[0011] 4) jackets (8) along each external side for the fine Installationof various piping.

[0012] 5) a sheet of wood-fibres (5) in this case, not bonded tightly isthen placed on the synthetic profiles (4) thereby closing the frame ofthe panel before closing the mold and injecting the expandable products.

[0013] 6) the injection of expandable reactive products (9) which afterpolymerization, function to fill the cavity, completely bonding all thecomponents Comprising the future panel. The panel, thereby becoming onepart (contiguous) and very strong is removed from the mold.

[0014] The present invention is characterized by the fact that the plateis not air tight, allowing the evacuation of the excess air (6) whileallowing the impregnation of part (7) of the thickness of the plate (5),by the expandable material (9). The panel presents a rough outsideexterior for the future application of a polymeric cement surfacecoating, on the building site.

[0015] The present invention offers the advantage of equally fabricatingstraight (11) or angled (12) elements by following the same technique,the external profiles (2) of the future panel are positioned in the moldperpendicularly to the face of the panel and themselves assembled by theappropriate metal gussets (13). This avoids the need for angle beams forthe panel set-up.

[0016] The panels obtained in this manner are entirely closed on alltheir edges, the longitudinal side is in the form of a U shape forconnecting the panels.

[0017] The present invention relates to the method of using the panels.At the end of junction tube (16) are welded metal pieces (17) comprisinga thread (22) and a face (21). This junction tube (16) is incorporatedinto the profiles (2) forming edges in the form of a U shape on thebottom side of the panels (17), the connection to the tube is fixed withexpansion bolts (2), rendering the tube (16) and the masonry (24) solidwithout having reserved niches linked to the ground (foundation).

[0018] PVC tube (18) is positioned inside the junction tube (16), and isitself maintained by fitting in the surface (21) of metal pieces (17).

[0019] The second panel is also encased at the linking tube (16), andsolidified by metal screw (25) crossing the profile (2) and the linkingtube (16). This assembly thereby attaches the two panels to the ground.

[0020] The present invention is characterized by the chemical foam thatlinks the panels together. The PVC tube (18) positioned inside thelinked panels, has holes (20) well spread along it's length. allowingthe distribution of foam product (9) on (into) the connecting assemblyof the two panels. The injection is made at the upper part of theconnecting tube (16) across drilled plate (17), expansion beingcontrolled by the position of the nut (19) screwed onto the plate (17).

[0021] The present invention allows for a chemical mechanical connectionbetween panels insensitive to weathering and stress. The injection tothe interior of the tubes (18) can be made soon after the installationof the two panels or later without any problem.

[0022] The present invention assures a very strong link between theground and the frame, made possible by the connecting tube (16) attachedto the upper and lower pan by bolting onto the plates (17).

[0023] The present invention allows one to obtain an assembly of strongbeams at each end of the panel, through the solid construction of theprofiles (2) and the connecting tube (16) the beam for the angle (12)being of the same concept as the straight coupling beams (11).

THE FOLLOWING DRAWINGS SHOWS THE PRESENT INVENTION

[0024]FIG. 1 represents: vertical section (line) of the panel

[0025]FIG. 2 represents: horizontal section (line) of a right connectedpanel

[0026]FIG. 3 represents: vertical section (view) of the bottom of thepanel

[0027]FIG. 4 represents: horizontal section (view) of angled panels

[0028]FIG. 5 represents: vertical section (view) of panel linked toground and frame

[0029]FIG. 6 represents: the pour in place (view) of the panelcomponents in the mold

[0030]FIG. 7 represents: frame fabrication-angled and straight

[0031]FIG. 8 represents: a section (view) of a panel type

1) The present invention concerns the factory fabrication of insulated,weather resistant panels by incorporating into the mold the(furnishings) materials for obtaining these said panels and notably themetallic profile assemblies (2) with gussets (3), (13) for thefabrication of panels joined at right angles. (11) or variable angles(12). 2) The present invention is characterised by the use of porousplates (5), to allow the evacuation of the excess air (6), of which theexpandable material (9) penetrates only partly through the thickness ofthe porous plate thereby enabling the face not impregnated with the foamproduct to accept a future coating. 3) The present invention ischaracterized by the incorporation, during the preparation of the panelmold, jackets (8) for the future placement of different wiring after theinstallation of the panels on site. 4) The present invention ischaracterised by a tight sealed connection (26) between two panels, thelink made weather resistant, by the injection of expandable product (9)inside a a special tube (13) having holes (20) well spread along thetube, allowing the uniform spread of the expandable product. 5) Thepresent invention is characterized by the link between bottom partconnected to the ground (24) and the upper part of the panel (27)attached solidly to the frame. The connecting profile (16) provided withplate (17) renders the panels solid to the ground and the frame. 6) Thepresent invention is characterized by the absence of provisional nichesbeing provided and before being subsequently filled, after the linkbetween the panels and their attachment to the ground, through thepresence of the junction tube (16) with which the connection to theground is realized with the aid of pin (23) a foam or chemical sealant,avoiding all the complex reservations (set-up) THIS IS STILLUNINTELLIGIBLE AND NEEDS MORE WORK. 7) The present invention allows fora water tight seal (26), at the set-up of two panels or after theconnection of the necessary panel assemblies at the construction site.